CZ304070B6 - Method of producing prefabricated elements and apparatus for making the same - Google Patents

Abstract

The invented method of producing prefabricated elements by making use of waste materials is characterized in that a mixture comprised predominantly from waste materials such as plastics forming a base component of binding agents, is filled in a closed mold wherein plastic with a lower melting temperature, such as polyethylene and polystyrene, are incorporated in the mixture preferably as a part of a crushed material or as a part of granules, wherein plastics with higher melting temperature, such as PET bottles, preferably form a base component of plastics mixed in the mixture in the form of shredding and/or closed containers. Further filler is added in the mixture wherein the base components of the filler are clay loam such as waste brick loam and natural materials of the straw or reed type, most preferred in the form shredding, whereupon the mixture is heated to a temperature in the range of 120 degC to 240 degC under simultaneous compression and pressure of the mixture to the walls of the closed mold. The natural additional binding agents are represented by resins comprised in the natural materials and agglomerated cakes of organic contamination of the waste components formed during roasting of the mixture and/or other used waste materials with melting temperature below 200 degC and/or solids dissolved in the roasted mixture liquid component, which evaporates during roasting, whereby the ratio of the components used is selected according to the given requirements for thermal and mechanical properties of the prefabricated element being produced. Apparatus for making the above-described method comprises a closed mold (21), with internal thermally insulating macro-cavities being formed therein by means of PET bottlers (1) with plastic caps (5) having lower melting temperature if compared with PET bottles (1). The bottoms of the PET bottles (1) rest on lower supports (8) performed on the bottom of the closed mold (21) and copying the shape of the molded depression in the PET bottle (1) bottoms and the caps (5) are arranged in upper supports (7) anchored in the lid of the mold (21). Each upper support (7) is provided with a hollow pin (9) with an external piston (10), where this hollow pin (9) protrudes via a check valve (11) into a common air bleeding space (12) with outlets of all the check valves (11) and wherein this air bleeding space (12) has its outlet via an adjustable pneumatic resistance (13) outside the closed mold (21).

Description

Technical field

The invention relates to building materials for the production of small prefabricated building elements with maximum utilization of waste materials and waste energy, in particular heat. The invention originated as part of the development of a system for the construction of extremely ecological and complex economic housing usable even in the poorest areas.

BACKGROUND OF THE INVENTION

There are a number of established systems of production and modular construction of residential buildings based on the use of modular elements of small prefabrication. However, their further development appears to have been completed, as there is no longer a significant chance of improving key parameters such as comprehensive energy efficiency and environmental friendliness.

The most promising way to improve these parameters appears to be the maximum utilization of waste materials, especially plastics. A number of not only simple recycling processes for the recovery of waste plastics with a requirement of varying degrees of separation are known. In construction, these are usually tiles and other elements of reinforcing clay surfaces. The load-bearing building components are then generally stored in plastic waste in the heat-insulating cavities of the prefabricated components. The closest solution to the present invention is the solution according to CZ 299 223, which recommends admixing unsorted waste plastic in granular form as a filler component of the concrete mix for the production of building components and after hydration of the cement binder by heating up to 200 ° C. lower melting points ensure their use as an additional binder.

The disadvantage of the previously known technologies for the production of supporting building elements of small prefabricated masonry is the need for special firing energy-intensive technologies for firing ceramic shards, cement production, etc., making them unsuitable for technically underdeveloped areas. In these areas are the most widespread prefabricated buildings made of mud, most commonly called adobe. The disadvantage of this building material is its very low resistance to moisture and repeated freezing; moreover, this solution does not contribute to environmental protection against the most frequent variant of infestation of backward areas by plastic packaging of goods imported from technically advanced areas. In the case of the use of molten plastics as an additional binder, as is the case with the patent CS 299 223, the problem of desirably pressurizing the plastic binder into the joints of the cemented structure is not solved.

SUMMARY OF THE INVENTION

The disadvantages of the previously known technology and systems for the production of small prefabricated elements for the modular construction of residential buildings significantly reduce the new advantages and benefits of the method of manufacturing prefabricated components using waste materials and equipment for its implementation according to the present solution. It is based on the fact that a mixture consisting mainly of waste materials consisting mainly of plastics, constituting the basic component of the binders, is placed in a closed baking mold. Low melting point plastics, such as polyethylenes and polystyrenes, are preferably incorporated into the fused mixture as part of the pulp or granules. High melting point plastics, such as PET bottles, are preferably the base component of the plastics admixed in the baking mixture in the form of chopped and / or sealed containers. Further, a filler is added to the mixture, the basic components of which are clay clays, for example waste brick clays and natural materials of the straw or reed type, most preferably in the form of a chop. The resulting mixture is heated to a temperature in the range of 120 ° C to 240 ° C while compressing and pressing the baking mixture to the walls of the closed baking mold. Natural supplementary binders are resins contained in natural materials and the organic contamination of waste components resulting from baking of the mixture and / or other waste materials used with a melting point below 200 ° C and / or solids dissolved in the liquid baking component. a mixture which evaporates during baking. The relative amount of the individual components of the mixture used is selected according to the specified requirements for thermal and mechanical properties of the manufactured prefabricated component.

When heat-insulating prefabricates are produced in this way, straw is used as a natural material in compressed mats, which are wrapped in a plastic foil and are interwoven with plastic PET clips.

In one possible embodiment, the baking composition in the closed baking mold is compressed and pressed against the walls of the mold by expanding the gases and vapors enclosed in the plastic containers contained in the baking composition. The expansion of these sealed plastic containers is made possible by their plasticization induced by increasing the temperature of the sealed containers during baking.

Advantageously, closed PET bottles are used to compress the baking composition and press it against the walls of the closed baking mold. The pressing pressure at the fusing temperature is then selected by the water content of the sealed PET bottle filling and the PET bottle cap is used as a pressure fuse.

In the production of thin-walled thermal insulating prefabricated components with a minimum mineral filler content, the thermal expansion of the closed-structure foam materials is utilized after pressing the baking mixture to the walls of the closed baking mold. Such a material is, for example, preferably expanded polystyrene, which, after fulfilling the function of a pneumatic press, melts further and fulfills the function of a plastic binder of the components of the mixture which only plastically reshape under pressure such as straw choppers.

It is very advantageous to use the waste heat of large-scale power plants for heating to the fusing temperature.

One type of device that allows the above method of manufacturing prefabricated elements is a closed baking mold device in which internal heat-insulating macrocavities are formed by PET bottles with a plastic cap having a lower melting temperature than PET bottles. The bottom of the PET bottles is seated on the lower supports formed on the bottom of the closed baking mold. These bottom supports roughly follow the shape of the indentation in the bottom of the PET bottle. PET bottle caps are housed in the upper supports anchored in the lid of the sealed baking mold. These upper supports are preferably a mirror image of the lower supports, so that the shape of the decals of the lower and upper supports forms together a locking system on the walls of the toasted precast product. Each of these upper supports is provided with a hollow mandrel with an external piston. The hollow mandrel is led through a non-return valve into a common venting space where all non-return valves are connected. The venting space is further discharged through an adjustable pneumatic resistance outside the sealed mold.

In another embodiment, in the manufacture of thin-walled heat-insulating building prefabricated elements using a straw mat interwoven with staples and provided with a bag-shaped wrapping film open on the anticipated drip side of the baked prefabricated device, the device is realized such that PET supplementary buckles. Preferably, at least a portion of these complementary clips may be crimped into the clamping cup structure by their lower end. The cup structure is further provided with preformed locking profiles which correspond in shape and position to the locking shape selected by the shape of the inner walls of the closed baking mold. The internal source of the compression pressure here is a expanded polystyrene pulp or a granular semi-finished product for the manufacture of expanded polystyrene, which is freely mixed into the baking mixture.

-2GB 304070 B6

The main advantage of the solution according to the invention is the ability to use precisely those municipal waste components that are least desirable for landfills. These are mainly plastic waste, even in unsorted and uncleaned form. The prerequisite for the extremely low production cost is that all other material components of the baking mixture are of a rather waste character, and even heating to the baking temperature can be provided by the waste heat of the thermal power equipment, in reality often only wasted in cooling systems.

From the point of view of self-production in underdeveloped localities, the possibility of use for baking similar facilities as required by baking food preparation is important.

Exterior washable surfaces can be provided by applying the desired dye and grain structure, preferably in the form of a water emulsion coating, to the respective wall of the closed mold, most preferably to the bottom of the mold.

Overview of the drawings

A schematic representation of a mold of a basic modular support element is shown in Fig. 1 and Fig. 2 is a schematic representation of a mold for baking roof heat insulating large-area prefabricates.

DETAILED DESCRIPTION OF THE INVENTION

The new technological principles for the production of prefabricated building elements according to the invention are explained on the examples shown in the figures.

Giant. 1 serves to describe the production of the basic modular element of the load-bearing peripheral masonry and FIG. 2 to describe the manufacture of heat-insulating elements, for example large-area heat-insulating elements of roofing.

In the method for the production of baked-on precast products, the waste plastics in the baked-on waste material mixture form a basic binder component, with lower melting point plastics such as polyethylenes and polystyrenes being a major component of unsorted pulp or granules. High melting point plastics, such as PET bottles, are coarsely recycled and form an essential component of the plastics admixed in the baking mixture, either in the form of chopped or closed containers. Clay fillers, preferably waste brick clay and natural materials such as straw or reeds in the form of chopped material are the basic fillers of the mixture. Natural supplementary binders are resins contained in natural substances and caking of organic contamination of waste components of the baked mixture and other crushed waste materials with a melting point below 200 ° C. Water and other liquid components of the mixture evaporate during baking.

In one possible embodiment, as shown in FIG. 1, closed plastic PET bottles 1, supported by bottom supports 8 on the bottom of the closed baking mold 21, are used to press the mixture deposited into the closed baking mold 21. These PET bottles I are used as a pneumatic press for compressing and pressing the baking mixture against the walls of the closed baking mold 2L The pressing pressure at the baking temperature is selected by the water content of the filling in the closed PET bottles L Plastic cap 5 PET bottles 1 anchored in the lid of the closed baking mold 21 is used as a temperature-pressure fusible fuse such that the upper supports 7 on the side of the shutters 5 are provided with a piston 10 with a hollow darkness 9 on its face. only from the PET bottle cap 5 by the hollow mandrel 9 to the venting space 12 of the closed baking mold 21 provided with an adjustable adjustable pneumatic resistance 13.

The basic prefabricated element of the bearing masonry is supposed to maintain the external shape and the placement of internal thermal insulation macrodutin, which are formed in the prefabricated

It is possible to design it with 12 PET bottles 1 with a volume of 1.5 liters, as it appeared to be optimal for a modular system made on the basis of a precast concrete using a cement binder.

The prefabricated part according to the invention can also be made by means of a mold and a pressure system intended for the production of prefabricated concrete. However, in order to reduce the cost of minimal technological equipment, the molding process of the present invention utilizes thermal expansion of gases and vapors in closed PET bottles 1 for molding a baked mixture consisting of plastic granules in the form of granules 2 and band-shaped chop 3 into mold 21.

As already mentioned, the thermal pressure fuse is provided by a standard plastic closure 5, which is made of lower melting temperature plastics, which loses its ability to perform the closure 5 of this PEZ bottle 1 when it exceeds the presumed combination of pressure and temperature in the PET bottle 1. to deform the internal partitions 6 between the cavities at the time of the loss of cap function 5 of any of the PET bottles 7, the upper supports 7 of the PET bottles 1 of the sealed baking mold 21 are provided with hollow mandrels 9 with an external piston 10. check valve 11 into common vent space 12, which is vented via an adjustable pneumatic resistor 12. Compressed gases released into common vent space 12 will temporarily increase overpressure in this space, actuating the pistons 10 of the hollow mandrels 9 of the remaining upper PET bottle supports 7 1, thereby piercing the closures 5 of the other PET bottles 1 and thus allowing simultaneous deaeration of all pressurized PET bottles 1 and thus completing the molding and compacting stage of the baking mixture at a temperature close to the selected baking temperature. The shape of the lower supports 8 on the side of the bottles 1 is in this example a mirror image or a decal of the supports 7 and is the basis of the locking system after the so-called dry walling.

The example shown in Fig. 2 is an alternative to the application of the invention in the manufacture of heat-insulating prefabricates with reduced rigidity and strength requirements such as prefabricated heat-insulating covering. A common feature of these heat-insulating prefabricates is that they use a mixture with a minimum content of mineral fillers, i.e., minimized soil and other mineral non-foamed fillers 4 for baking, so that the essential constituents of fillers 4 are PET material from plastic waste, preferably in the form of compressed mats provided with a plastic film wrap. In order to press the baking mixture against the walls of the closed baking mold 21, a thermal expansion of the closed structure foam materials, preferably foamed polystyrene, is used here, which upon melting the pneumatic press melts and performs the plastic binder components of the mixture. the temperature of the expanded components merely plastically reshape and the components that are moved at this stage, such as straw chop. Here again, the waste heat of large-scale power plants such as thermal power plants, incinerators, brickworks, etc. can be used for heating to the fusing temperature.

In an exemplary representation of a device for manufacturing a roofing prefabricated component, a two-phase baking is envisaged. In the first stage, a thermoformed plastic waste in which the PET material is predominantly produced is thermoformed, the lower clamping tray structure 15 of the prefabricated element, it being preferred that at least a portion of the plastic PET buckles 16 of the straw mat 17 are already crimped at this stage into the cup structure 15.

In serial production, it will be preferable to produce the plastic tray structure blank 15 by bonding the rolled sections 18 with a plastic wrapping foil 19 whose melting temperature is lower than the baking temperature. This wrapping sheet 19 may also be the basis of the impermeability of the upper wall of the heat insulating elements to be produced and together with the lower cup structure 15 form a formation open only in the eaves so that any moisture from inside the heat insulating elements may drain or be released from the space in the form of water vapor. The orientation of the closed baking mold 21 during baking is chosen according to the interest of which wall to be reinforced with the excess molten plastic or, conversely, of the interest of preserving the natural appearance of the exterior side, for example thatch.

-4GB 304070 B6

It is only in the second stage of baking that the baking mixture is pressed. Here, the function of the internal pressure source in the form of closed plastic containers will be provided by the expanded polystyrene or granular polystyrene pulp 20, whose foaming occurs only during heating to the fusing temperature. Since the fusing temperature will be greater than the melting point of polystyrene, the foam adds gradually to the task of pressing the fusing mixture against the walls of the closed baking mold 21 during heating, thereby relocating the natural filler components 4, e.g. PET waste. Further heating will melt the polystyrene component, which due to its wettability and honeyiness adheres to the natural components of the filler 4 and PET plastic noodles 3 or flows to the bottom of the closed baking mold 21, where after solidification it solidifies the prefabricated side. baking molds 21. The solidification of the molten plastics which adhere to the other components increases the rigidity, load-bearing capacity and shape stability of the prefabricated component, in particular by cementing the contact points of these components with the solidified adhesive. In the position of the baked-on prefabricated exterior on the bottom, the result may not be to create a surface suitable, for example, for bonding another insulating or photovoltaic layer, but for example a clay surface can be imitated by clay spreading.

Industrial applicability

Although the main field of industrial application is described in the examples, the solution according to the invention is a general way of saving cement binder in the production of so-called building recyclates as well as elements of straw structures where it is not interested to demonstrate the straw character of these elements.

Claims (10)

PATENT CLAIMS 1. A process for the production of prefabricated building materials using waste materials, characterized in that a closed baking mold comprises a mixture consisting predominantly of plastic waste materials constituting the basic binder component, wherein lower melting plastics such as polyethylenes and polystyrenes, is preferably incorporated into the baking mixture as part of the pulp or granules, wherein the higher melting point plastics, such as PET bottles, are preferably the base component of the plastics admixed in the baking mixture in the form of chopped and / or sealed containers; the basic constituents are clay clays, such as waste brick clays and natural materials of the straw or reed type, most preferably in the form of a chop, whereupon the mixture is heated to a temperature of 120 ° C to 240 ° C while compressing and pressing the baked mixture against the walls baking molds, wherein the natural complementary binders are resins contained in natural materials and cakes of organic contamination of waste components resulting from baking the mixture and / or other waste materials used with a melting point below 200 ° C and / or solids dissolved in the liquid component of the baking mixture , which evaporates during baking, the relative amount of the individual components of the mixture used is selected according to the specified requirements for thermal and mechanical properties of the manufactured prefabricated component. Method according to claim 1, characterized in that, in the case of the production of heat-insulating prefabricated elements, straw is used as natural material in compressed mats provided with a plastic foil (19) of plastic and interwoven with plastic PET clips (16). Method according to claim 1, characterized in that the baking mixture in the closed baking mold is compressed and pressed against the walls of the mold by expanding the gases and vapors enclosed in the plastic containers contained in the baking mixture which allow this expansion by their plasticizing induced increase in temperature. during baking. -5GB 304070 B6 Method according to claim 3, characterized in that the baking mixture is compressed and pressed against the walls of the closed baking mold by closed PET bottles, wherein the pressing pressure at the baking temperature is selected by the water content of the closed PET bottle filling and the PET bottle cap is used as a pressure melt fuse. Method according to claims 2 and 3, characterized in that in the production of thin-walled heat-insulating prefabricated building blocks with a minimum mineral filler content, thermal expansion of closed-state foamed materials such as expanded polystyrene is used to press the baked mixture against the walls of the closed baking mold. after performing the function of the pneumatic press by further heating, it melts and acts as a plastic binder of the mixture components which only plastically deform during the pressure action of the temperature-expanded components and of the components which are moved during this pressure baking stage, such as straw chop. Method according to any one of claims 1 to 5, characterized in that the heating to the fusing temperature is carried out by utilizing the waste heat of large-scale power plants. Device for carrying out the method according to claims 1, 3, 4 and claim 6, comprising a closed baking mold, characterized in that, in the closed baking mold (21), by means of PET bottles (1) with a plastic cap (5) with lower melting temperature. than the PET bottles (1) have internal thermal insulating macrocavities, wherein the bottom of the PET bottles (1) is seated on the lower supports (8) formed on the bottom of the sealed baking mold (21) and following the shape of the indentation in the bottom of the PET bottle (1) 5) are mounted in upper supports (7) anchored in the lid of the closed baking mold (21), and each of these upper supports (7) is provided with a hollow mandrel (9) with an external piston (10), the hollow mandrel (9) via a non-return valve (11) it opens into a common venting space (12), where all the non-return valves (11) are connected and where this venting space (12) opens through an adjustable pneumatic resistor (13) outside the closed forging molds (21). Device according to claim 7, characterized in that the upper supports (7) are a mirror image of the lower supports (8), so that the shape of their decals forms together a locking system on the walls of the toasted precast product. Device for carrying out the method according to claims 1, 2, 3, 5 and claim 6, comprising a closed baking mold, characterized in that in the production of thin-walled thermal insulation prefabricated elements using a straw mat (17) interwoven with clips (16) and provided with a packaging film (19) of the bag-shaped shape open on the supposed eaves side of the baking prefabricated part, the bottom of the closed baking mold (21) is provided with a clamping cup structure (15) with plastic PET filler clips (22), and the cup structure (15) is provided with preform (18) which correspond in shape and position to the lock shape selected by the shape of the inner walls of the closed baking mold (21), wherein the internal source of compression pressure consists of a polystyrene foam grit (20) or granular foamed polystyrene blank admixed into the baking mixture. Method for carrying out the method according to claim 9, characterized in that at least a part of the additional clips (22) is pressed into the clamping cup structure with its lower end.